Sulfur-free dissolving pulps and their application for viscose and lyocell

In this study, the concept of multifunctional alkaline pulping has been approved to produce high-purity and high-yield dissolving pulps. The selective removal of hemicelluloses was achieved by either water autohydrolysis (PH) or alkaline extraction (E) both applied as pre-treatments prior to cooking. Alternatively, hemicelluloses were isolated after oxygen delignification in a process step denoted as cold caustic extraction (CCE). Eucalyptus globulus wood chips were used as the raw material for kraft and soda-AQ pulping. In all process modifications sulfur was successfully replaced by anthraquinone. By these modifications purified dissolving pulps were subjected to TCF bleaching and comprehensive viscose and lyocell application tests. All pulps met the specifications for dissolving pulps. Further more, CCE-pulps showed a significantly higher yield after final bleaching. Morphological changes such as ultrastructure of the preserved outer cell wall layers, specific surface area and lateral fibril aggregate dimension correlated with the reduced reactivity towards regular viscose processing. The residual xylan after alkali purification depicted a lower content of functional groups and a higher molecular weight and was obviously entrapped in the cellulose fibril aggregates which render the hemicelluloses more resistant to steeping in the standard viscose process. Simultaneously, the supramolecular structure of the cellulose is partly converted from cellulose I to cellulose II by the alkaline purification step which did not influence the pulps reactivity significantly. Nevertheless, these differences in pulp parameters did not affect the lyocell process due to the outstanding solubility of the pulps in NMMO. Laboratory spinning revealed good fiber strength for both, regular viscose and lyocell fibers. The high molecular weight xylan of the CCE-treated pulps even took part in fiber forming.     

Progress in cellulose shaping: 20 years industrial case studies at Fraunhofer IAP

Cellulose, the most abundant renewable organic material on earth, exhibits outstanding properties and useful applications, but also presents a tremendous challenge with regard to economical and environmentally friendly chemical processing. The viscose process, more than 100 year old is still the most widely utilized technology to manufacture regenerated cellulose fibers and films. Viscose fibers are produced today worldwide on a 5 million ton scale with various fiber types ranging from high performance tire yarn to textile filaments and staple fibers with excellent properties close to those of cotton. At Fraunhofer IAP, the technical equipment for viscose preparation, wet spinning of fibers, hollow fibers, and tube-like films is available on a min-plant scale. Research focused on raw materials testing, process optimization with regard to economic and ecological aspects, structural analysis of cellulose during processing, and structure–property relations of fibers and films. Similar to the viscose process, cellulosic fibers can be produced via cellulose carbamate as an environmentally friendly route. In a close cooperation of Fraunhofer IAP with industrial partners, a specific process based on cellulose carbamate was developed on a pilot plant scale, giving fiber properties close to those of conventional viscose fibers. In recent decades the N-methylmorpholine-N-oxide (NMMO)-technology turned out to be a nonderivatizing commercial alternative to the still dominant viscose route. From the very beginning, Fraunhofer IAP has been engaged in investigating the structure formation of cellulose fibers precipitated from NMMO-water solution, revealing structural reasons for the fibrillation tendency of these fibers and means to overcome them. Starting from fiber formation via dry-jet wet spinning, for the first time the blown film formation and the meltblown nonwovens technology were developed for cellulosics on a pilot plant scale at Fraunhofer IAP. Based on the elastic behavior of the dope at elevated temperatures, cellulose can be processed like a melt in the air-gap, offering new possibilities of shaping cellulose like meltable mass polymers. Combining cellulose carbamate with NMMO-monohydrate as a solvent, higher polymer concentrations in the dope and outstanding mechanical properties of the resulting fibers were achieved.     

In-situ synthesis,characterization and antimicrobial activity of viscose fiber loaded with silver nanoparticles

In order to broaden applications of viscose fiber, graft copolymerization of acrylic acid was conducted on its surface followed by in situ loading of Ag nanoparticles (Ag-NPs). The loading amount of Ag-NPs was affected by the concentrations of Ag⁺ and trisodium citrate, and their optimum concentrations were found to be 0.014 and 0.030 g/ml. The Ag-NP-loaded fibers presented a prolonged Ag release behavior in aqueous solution, of which the cumulative release was less than 5 % within 48 h. In addition, the viscose fibers showed good antimicrobial activity against S. aureus, and their consecutive antimicrobial activity was kept at more than 90 % after several washing cycles. Modified viscose fibers, therefore, offer a great opportunity for use as antimicrobial fabrics.     

Degradation of viscose fibers during acidic treatment

Novel developments in the fiber sector require additional investigation of their behaviour during the production process. In the core step of the viscose process, cellulose fibres are regenerated in an acidic spinning bath. To investigate the influence of hemicellulose content and temperature on the kinetics of fiber degradation, standard and hemicellose-enriched fibers were treated in the acidic standard spinning bath for time periods up to 292 h. Viscose samples of different hemicellulose content were prepared under standardized conditions and the never dried fibres were subjected to long term degradation in the standard spinning bath at 40, 50 and 60 °C. The changes in the degree of polymerization (DP), molar mass distribution, hemicellulose and the generation of the total organic carbon in the spinning bath were monitored. Further, the changes in crystallinity and the level-off-DP of the fibers were determined to improve the accuracy of the existing degradation model. Changes in morphology of the fibers were monitored by optical microscopy and scanning electron microscopy.     

Short cellulose nanofibrils as reinforcement in polyvinyl alcohol fiber

Short cellulose nanofibrils (SCNF) were investigated as reinforcement for polyvinyl alcohol (PVA) fibers. SCNF were mechanically isolated from hard wood pulp after enzymatic pretreatment. Various levels of SCNF were added to an aqueous PVA solution, which was gel-spun into continuous fibers. The molecular orientation of PVA was affected by a combination of wet drawing during gel spinning and post-hot-drawing at a high temperature after drying. A maximum total draw ratio of 27 was achieved with various SCNF contents investigated. The PVA crystal orientation increased when small amounts of SCNF were added, but decreased again as the SCNF content was increased above about 2 or 3 %, likely due to SCNF percolation resulting in network formation that inhibited alignment. SCNF fillers were effective in improving PVA fiber tensile properties (i.e., ultimate strength and elastic modulus). For example, the ultimate strength and modulus of PVA/SCNF composite fiber with a SCNF weight ratio of 6 were nearly 60 and 220 % higher than that of neat PVA. Shifts in the Raman peak at ~1,095 cm^?1, which were associated with the C–O–C glycosidic bond of SCNF, indicated good stress-transfer between the SCNF and the PVA matrix due to strong interfacial hydrogen bonding. Cryogenic fractured scanning electron microscopy images of filled and unfilled PVA fibers showed uniform SCNF dispersion.     

Preparation of cellulosic fibers with biological activity by immobilization of trypsin on periodate oxidized viscose fibers

In this study, a biologically active fibrous material was designed by immobilizing trypsin on viscose fibers. The viscose yarn was first oxidized with sodium periodate to produce aldehyde groups and then employed as a support for subsequent immobilization of trypsin through bovine serum albumin. The oxidation by sodium periodate caused changes in the chemical and physical properties of the modified yarn samples, which were evaluated by determining the aldehyde group content, fineness and tensile strength of yarn. The viscose fibers oxidized under the most severe conditions (0.4 % NaIO₄, 360 min) exhibited the maximum amount of introduced aldehyde groups (1.284 mmol/g), but also the highest decrease in tensile strength. The trypsin activity was assayed with N-α-benzoyl-DL-arginine p-nitroanilide hydrochloride, whereas the amount of bound trypsin was determined by Bradford method. Trypsin immobilized on oxidized viscose yarn retained 97.3 and 83.8 % of the initial activity over 60 days of storage at 4 and 25 °C, respectively, and remained firmly attached to the carrier. The potential application of obtained bioactive fibers is in the treatment of wounds.     

Structure and properties of regenerated cellulose fibers from aqueous NaOH/thiourea/urea solution

Regenerated cellulose fibers were successfully prepared through dissolving cotton linters in NaOH/thiourea/urea aqueous solution at ?2 °C by a twin-screw extruder and wet-spinning process at varying precipitation and drawing conditions. The dissolution process of an optimized 7 wt% cellulose was controlled by polarizing microscopy and resulted in a transparent and stable cellulose spinning dope. Rheological investigations showed a classical shear thinning behavior of the cellulose/NaOH/thiourea/urea solution and a good stability towards gelation. Moreover, the mechanical properties, microstructures and morphology of the regenerated cellulose fibers were studied extensively by single fiber tensile testing, X-ray diffraction, synchrotron X-ray investigations, birefringence measurements and field-emission scanning electron microscopy. Resulting fibers demonstrated a smooth surface and circular cross-section with homogeneous morphological structure as compared with commercial viscose rayon. At optimized jet stretch ratio, acidic coagulation composition and temperature, the structural features and tensile properties depend first of all on the drawing ratio. In particular the crystallinity and orientation of the novel fibers rise with increasing draw ratio up to a maximum followed by a reduction due to over-drawing and oriented crystallites disruption. The microvoids in the fiber as analysed with SAXS were smaller and more elongated with increasing drawing ratio. Moreover, a higher tensile strength (2.22 cN/dtex) was obtained in the regenerated fiber than that of the viscose rayon (2.13 cN/dtex), indicating higher crystallinity and orientation, as well as more elongated and orientated microvoid in the regenerated fiber. All in all, the novel extruder-based method is beneficial with regard to the dissolution temperature and a simplified production process. Taking into account the reasonable fiber properties from the lab-trials, the suggested dissolution and spinning route may offer some prospects as an alternative cellulose processing route.     

Production of highly conductive textile viscose yarns by chemical vapor deposition technique: a route to continuous process

An oxidative chemical vapor deposition (OCVD) process was used to coat flexible textile fiber (viscose) with highly conductive polymer, poly (3,4‐ethylenedioxythiophene) (PEDOT) in presence of ferric (III) chloride (FeCl₃) oxidant. OCVD is a solvent free process used to get uniform, thin, and highly conductive polymer layer on different substrates. In this paper, PEDOT coated viscose fibers, prepared under specific conditions, exhibited high conductivity 14.2 S/cm. The effects of polymerization conditions, such as polymerization time, oxidant concentration, dipping time of viscose fiber in oxidant solution, and drying time of oxidant treated viscose fiber, were carefully investigated. Scanning electron microscopy (SEM) and FT‐IR analysis revealed that polymerization of PEDOT on surface of viscose fiber has been taken place and structural analysis showed strong interactions between PEDOT and viscose fiber. Thermogravimetric analysis (TGA) was employed to investigate the amount of PEDOT in PEDOT coated viscose fiber and interaction of PEDOT with viscose fiber. The effect of PEDOT coating on the mechanical properties of the viscose fiber was evaluated by tensile strength testing of the coated fibers. The obtained PEDOT coated viscose fiber having high conductivity, could be used in smart clothing for medical and military applications, heat generation, and solar cell demonstrators. Copyright © 2010 John Wiley & Sons, Ltd.     

A precise study on the feasibility of enzyme treatments of a kraft pulp for viscose application

The development of efficient process steps to convert paper-grade to dissolving pulps was investigated as part of the work programme to improve the process economics. The challenge of pulp refinement comprises the selective removal of hemicelluloses and the precise adjustment of the pulp viscosity, while maintaining the reactivity of the pulp as required for viscose application. The purpose of this study was to investigate the effects of various enzyme treatments on a commercial oxygen-delignified Eucalyptus globulus paper-grade kraft pulp in the course of a total chlorine free bleaching sequence in combination with refining techniques following the principle of Modified Kraft Cooking (Sixta et al. 2007). The objectives were to assess its applicability as viscose pulp besides the reduction of chemical consumption in alkaline and ozone bleaching steps by means of xylanase pre-treatment and the controlled adjustment of final pulp viscosity utilizing endoglucanase post-treatment. Xylanase pre-treatment combined with cold caustic extraction at reduced alkalinity efficiently removed the hemicelluloses from the pulp and clearly increased the pulp brightness by extensive removal of hexenuronic acid side chains. The xylanase pre-treated pulp showed increased reactivity towards xanthation and high viscose dope quality in terms of particle content. The dependence of cellulose chain scission on the applied endoglucanase concentration was analyzed in detail, and this allowed precise viscosity reduction as well as reactivity increase. The differently treated pulps, with and without xylanase pre-treatment, were of very narrow molecular weight distribution and the quality of the spun fibers were very similar to those viscose fibers from commercial dissolving pulps.     

Splitting tendency of cellulosic fibers. Part 3: splitting tendency of viscose and modal fibers

The splitting tendency of viscose and modal fibers in aqueous alkali solutions of LiOH, NaOH, KOH and TMAH was investigated. The viscose fibers splitted up to 5–7 fibrils, whereas modal fibers splitted up to 2–4 fibrils depending on alkali type and concentration. The fibrillar structure of lyocell enables it to split more (15–20 fibrils) than viscose and modal fibers. Splitting occurs where internal stress of fiber is high due to different alkali or void distribution inside fiber. The splitting test couldn’t be achieved for viscose and modal fibers between 1 and 5 M concentration of NaOH and TMAH solutions due to breakage of fibers during test. Above 5 M concentration, no split can be observed due to even distribution of alkali inside fiber. Paper presented at the 7th World Textile Conference, AUTEX 2007, Tampere, Finland, 26–28 June 2007. Christian-Doppler Laboratory of Textile and Fiber Chemistry of Cellulosics is a Member of European Polysaccharide Network of Excellence (EPNOE), www.epnoe.org     

Structure and thermal properties of bamboo viscose,Tencel and conventional viscose fiber

Comparative investigations of new regenerated cellulosic fibers, bamboo viscose fiber and Tencel, together with conventional viscose fibers have been carried out to explain the similarity and difference in their molecular and fine structure. The analyses jointly using SEM, XRD and IR reveal that all the three fibers belong to cellulose II. Tencel consists of longer molecules and has a greater degree of crystallinity, while bamboo viscose fiber has a lower degree of crystallinty. TG-DTG-DSC study shows three fibers resemble in thermal behavior with a two-step decomposition mode. The first step is associated to water desorption, suggesting that bamboo viscose fiber holds better water retention and release ability, the second a depolymerization and decomposition of regenerated cellulose, indicating that Tencel is more thermally stable in this process than bamboo and conventional viscose fiber.     

Water Accessibilities of Man-made Cellulosic Fibers – Effects of Fiber Characteristics

The dynamic vapor water sorption and desorption experiments were performed on cellulosic fibers with different characteristics. The hysteresis between moisture sorption and desorption cycle at 10% relative humidity (RH) was independent on the total moisture regain and approximately 45% for all materials except for viscose fibers. Brunauer–Emmett–Teller surface volume (V_m) for moisture sorption and retention capacity of liquid water (WRV) were also measured. The V_m and WRV increase in proportion to the total amount of moisture sorption (M_inf(total)) in all specimen except in poplar fiber. The coefficients of parallel exponential kinetics (PEK) were estimated by the curve-fitting of experimental data of the moisture regain, and the influences of the fiber characteristics on the PEK coefficients, the moisture regain, the hysteresis, V_m and WRV are discussed. The total equilibrium moisture content in the viscose fibers was higher but the moisture uptake and release rate was slower than the lyocell and poplar fibers. The cationization and the modification of shape of cross section accelerated the total equilibrium moisture content in the viscose fiber. A drying process at low temperature enhanced both the equilibrium moisture content and the moisture uptake and release rate in lyocell fibers while a spin finish retarded them. The total equilibrium moisture content was heightened by the crosslinking of the fiber, however, no obvious effect of the crosslinking on the moisture uptake and release rate was found. Effects of the type of the specimen and linear density on the moisture accessibilities are also discussed.     

The flame retardancy of alginate/flame retardant viscose fibers investigated by vertical burning test and cone calorimeter

The smoldering weakness of alginate fibers can be effectively suppressed by simple blending with flame retardant viscose fibers. The char formed by flame retardant viscose fibers can prevent the heat transmission and suppress the smoldering of alginate.     

Effect of xylan in hardwood pulp on the reaction rate of TEMPO-mediated oxidation and the rheology of the final nanofibrillated cellulose gel

alkali-washed nanofibrillated cellulose (NFC) samples, obtained from hardwood kraft pulp, with different amounts of retained xylan were prepared to study the influence of xylan on the water-retention properties of NFC suspensions. In this study, NFC was produced using an oxoammonium-catalyzed oxidation reaction that converts the cellulosic substrate to a more highly oxidized material via the action of the nitroxide radical species 2,2,6,6-tetramethylpiperidine-1-oxyl. Reduction of the xylan content in NFC was achieved by cold alkali extraction of kraft pulp. The pulps were then oxidized to a set charge under constant chemical conditions, and the reaction time was determined. The xylan content of the feed pulp was found to have a large negative influence on the oxidation rate of the pulp, as the oxidation time shortened when xylan was removed, from 220 min (for 25.2 % xylan content) to 28 min (for 7.3 % xylan content). Following fibrillation by homogenization, the swelling of the NFC was determined by a two-point solute exclusion method. The distribution of hemicellulose over the fibril surface was observed by atomic force microscopy. Xylan was found to be distributed unevenly over the surface, and its presence increased the water immobilized within flocs of NFC, i.e., so-called network swelling. The swelling of the NFC had a large impact on its rheology and dewatering. Comparison of the morphological and swelling properties of the suspensions with their rheological and dynamic dewatering behavior showed that reducing the xylan content in NFC results in a weaker gel structure of the nanocellulose suspension. The results indicate that most of the water is held by the swollen structure by means of xylan particles trapped within the hemicellulose layer covering the fibril surface. Samples with high xylan content had high shear modulus and viscosity and were difficult to dewater.     

Characterization of new natural cellulosic fiber from kusha grass

The present research work aimed to characterize new natural cellulosic kusha fibers extracted from the kusha grass plants. The physical and chemical properties of kusha fibers such as cellulose content (70.58%), lignin (14.35%), wax content (1.52%), ash content (2.46%), moisture content (8.01%), and density (1.1025 g cc^?1) were identified. An X-ray diffraction of kusha fibers confirms the presence of cellulose with a crystalline index of 55.4%. Fourier transform infrared spectroscopy analysis was carried out to establish the certainty of using them as reinforcement fiber. Thermogravimetric analysis ensures thermal stability up to 357°C which is within the polymerization process temperature.     

Kinetic study of oxalic acid pretreatment of moso bamboo for textile fiber

In this study, samples of moso bamboo were hydrolyzed for textile fiber with oxalic acid under various process conditions. Saeman hydrolysis models were applied to predict the percentage of xylan remained in the substrate after pretreatment and the net xylose yield in the liquid stream. Kinetic constants for Saeman hydrolysis models were analyzed by an Arrhenius-type expansion which include activation energy and catalyst concentration factors. The result showed that the degradation activation energies of xylan and xylose were 97.27 and 136.38 kJ/mol, respectively. Then the kinetic of mathematical models were obtained. Furthermore, the reaction parameters of oxalic acid concentration (1–4 % w/w), reaction temperature (150–180 °C), and reaction time (5–60 min) were handled as a single parameter, combined severity, which ranged in the present study from 0.86 to 1.62. Using combined severity parameters, an optimal condition was achieved which was as the followings: oxalic acid 2.0 % w/w, 170 °C, and 20 min. Under these conditions, 2.3 g glucose/L and 13.65 g xylose/L were produced in the hydrolysate fraction, 54.1 % glucan and 10.8 % xylan were produced in the residue fraction.     

Enhanced removal of hemicelluloses from cellulosic fibers by poly(ethylene glycol) during alkali treatment

Enhancing removal of hemicelluloses from cellulosic fibers is of decisive importance for producing high-purity cellulose. In this study, poly(ethylene glycol) (PEG) was added to a cold caustic extraction (CCE) process to promote removal of hemicelluloses from a softwood sulfite dissolving pulp. The content of hemicelluloses was considerably decreased from 11.4 % in the original sample to 5.3 % in the PEG/CCE-treated sample under the studied conditions. This positive result of PEG addition can be explained by (1) improved inward penetration and diffusion of NaOH into the fiber structure and outward diffusion of hemicelluloses from the fiber structure to the bulk phase, and (2) enhanced fiber swelling due to inclusion of PEG in the fiber walls and improved NaOH diffusion. Moreover, the effects of PEG/CCE treatment on the distribution of hemicelluloses in the fiber walls and the molecular weight of the residual hemicelluloses in the resulting pulp were investigated.     

Preparation and Properties of Alginate/Water‐Soluble Chitin Blend Fibers

Water‐soluble chitin (half‐deacetylated chitin) was prepared from chitosan by N‐acetylation with acetic anhydride. Alginate/water‐soluble chitin blend fibers were prepared by spinning their mixture solution through a viscose‐type spinneret into a coagulating bath containing aqueous CaCl₂ and ethanol. The structure and properties of the blend fibers were studied with the aids of infrared spectra (IR), X‐ray diffraction (XRD) and scanning electron microscopy (SEM). structure analysis indicated good miscibility existed between alginate and water‐soluble chitin, due to the strong interaction from the intermolecular hydrogen bonds and electrostatic interactions. Best values for the dry tensile strength and breaking elongation were obtained when the water‐soluble chitin content was 30 wt%. The wet tensile strength and breaking elongation decreased with the increase of water‐soluble chitin content. The introduction of water‐soluble chitin in the blend fiber can improve the water‐retention properties of the blend fiber compared to pure alginate fiber. The fibers treated with aqueous solution of silver nitrate have good antibacterial activity to Staphylococcus aureus.     

Purification of cellulosic pulp by hot water extraction

Hot water extraction (HWE) of pulp in a flow-through reactor was evaluated as a method to purify paper-grade pulps. About 50–80 % of the xylan and up to 50 % of the lignin in unbleached birch Kraft pulp was extracted by the HWE without losses in cellulose yield. The residual xylan content in the extracted pulps was predominantly too high for dissolving-grade applications, but some of the pulps with a xylan content of 5–7 % might still be suitable as rayon-grade pulps. Increasing extraction temperature lowered the xylan content at which cellulose yield started to decrease. Furthermore, at any given xylan content, increasing extraction temperature resulted in cellulosic pulp with higher degree of polymerization. The extracted xylan was recovered almost quantitatively as xylo-oligosaccharides. The results suggest that HWEs at elevated temperatures may be applied to purify cellulosic pulps, preferably containing a low xylan content, and to recover the extracted sugars.     

Castor oil-based biopolyurethane reinforced with wood microfibers derived from mechanical pulp

Wood fibers with high lignin content show promise to function in numerous applications with advantageous properties if the fiber features are appropriately exploited. The present study introduces a new approach to disintegrate and disperse wood fibers from groundwood pulp (GWP) directly to polyol without additional solvent exchanges or chemical modifications. In comparison bleached chemical pulp with low lignin content was ground in the polyol, but only low consistency (1 wt%) operation was possible, whereas up to 5 wt% consistency with GWP was carried out with ease. The micron sized fibers in polyol were reacted with polymeric diphenylmethane diisocyanate to produce fiber reinforced biopolyurethane (bioPU) composites. The mechanical properties of the composites improved compared to reference bioPU showing 14.6% increase in Young’s modulus, 54.5% in tensile strength and 26.1% in strain at break. The tan δ peaks shifted to higher temperature from 5.5 to 10.4 °C when fibers up to 5.1 wt% were incorporated to bioPU. Overall, the bulk microfibers from GWP with low degree of processing were cost-effective reinforcements for bioPUs, which improved the qualities of the fabricated composites and showed good compatibility with polyurethane.